CN110040469B - System and method for monitoring tension of chain of scraper conveyor - Google Patents
System and method for monitoring tension of chain of scraper conveyor Download PDFInfo
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- CN110040469B CN110040469B CN201910306445.5A CN201910306445A CN110040469B CN 110040469 B CN110040469 B CN 110040469B CN 201910306445 A CN201910306445 A CN 201910306445A CN 110040469 B CN110040469 B CN 110040469B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
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Abstract
本发明公开了一种刮板输送机链条张力监测系统基方法，系统包括太赫兹波收发器，所述太赫兹波收发器通过支架单元固定在采煤机位于刮板链上方一侧的侧板上，用于生成一个或多个太赫兹波束，对传输中的刮板输送机链条进行探测扫描；防尘罩，设置在太赫兹波收发器外部，用于将外界环境粉尘与太赫兹波收发器隔离，防尘罩上设有一面由透明材料制成的工作面；刮粉机构，用于对防尘罩的工作面外表面的粉尘进行刮除；粉尘检测传感器，用于对防尘罩附近的粉尘量进行实时检测；控制器，所述太赫兹波收发器的信号输出端和所述粉尘检测传感器的信号输出端均与控制器的信号输入端连接，控制器的信号输出端与刮粉机构的信号输入端连接。
The invention discloses a basic method for a chain tension monitoring system of a scraper conveyor. The system includes a terahertz wave transceiver, and the terahertz wave transceiver is fixed on a side plate of a shearer located above the scraper chain through a bracket unit It is used to generate one or more terahertz beams to detect and scan the conveyor chain in transmission; the dust cover is set outside the terahertz wave transceiver and is used to send and receive external dust and terahertz waves. The dust cover is provided with a working surface made of transparent material; the powder scraping mechanism is used to scrape the dust on the outer surface of the working surface of the dust cover; the dust detection sensor is used to clean the dust cover The amount of nearby dust is detected in real time; in the controller, the signal output end of the terahertz wave transceiver and the signal output end of the dust detection sensor are both connected to the signal input end of the controller, and the signal output end of the controller is connected to the scraper. The signal input terminal of the powder mechanism is connected.
Description
Technical Field
The invention relates to the technical field of scraper conveyor monitoring and safety guarantee, in particular to a scraper conveyor chain tension monitoring system.
Background
The scraper conveyor is the main production transportation equipment of the fully mechanized working face under the coal mine, and undertakes the important tasks of transporting coal, providing a pushing fulcrum for a hydraulic support and providing a walking track for a coal mining machine, and the reliability of the scraper conveyor directly influences the safety and the benefit of the modern coal mine production.
The scraper chain (scraper, ring chain and chain connector) of the scraper conveyor has the functions of dragging, guiding, transmitting power and pushing coal, and is one of the key parts for determining the normal operation of the scraper conveyor. In the operation process of the scraper conveyor, due to the polygonal effect of a chain transmission system, frequent starting or stopping when the scraper conveyor is fully loaded or overloaded, and abnormal load effects such as caving of coal wall caving and coal wall collapse, the circular chain has vibration and impact characteristics, once tension is too large or too small, phenomena such as chain breakage, chain loosening and chain accumulation can occur, and according to statistics, 41.5% of scraper conveyor stopping is caused by chain breakage of the circular chain, and the normal production and production efficiency of a coal mine are seriously influenced. Meanwhile, the scraper conveyor runs under the working conditions of severe environments such as high temperature, humidity, top plate water spraying, dust and the like for a long time, and the invention is of great importance for the online tension monitoring technology of the round-link chain capable of working in the severe environments.
Current systems for monitoring the tension of a flight conveyor chain are: the Chinese patent with application number 201410060754.6, a tension detection device of a scraper conveyor, adopts a mode of punching a groove on the upper side of a chain and placing a sensor to monitor the tension of the chain in real time; the chinese patent with application number 201532274U, "tension measuring device for scraper conveyor chain", adopts the form of torque test wrench, mainly tests the tension of the chain of scraper conveyor when it is stationary.
The disadvantages of the above scheme are: the structure of the scraper chain is damaged, the bearing capacity of the scraper chain is reduced, chain breakage accidents are more likely to occur at the position where the sensor is placed, and safety accidents such as chain clamping and the like are more likely to occur due to the influence of the sensor when the position passes through the chain wheel; only the force in a static state can be tested, and real-time monitoring in the running process cannot be carried out. The scheme is only in a theoretical level and is not applicable to actual coal mines.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to overcome the defects in the prior art, and provides a practically-applicable nondestructive scraper conveyor chain deformation monitoring system and a stress calculation method, which can realize nondestructive monitoring of the tension of a scraper conveyor chain and effectively monitor the state of the scraper conveyor chain.
The technical scheme is as follows: in order to achieve the purpose, the invention adopts the technical scheme that:
a scraper conveyor chain tension monitoring system, the system comprising:
the terahertz imaging unit is used for detecting and scanning a scraper conveyor chain in transmission to generate a video or image signal of the chain, and comprises: the system comprises a terahertz wave transceiver, a terahertz image processing device, a support unit and a dust cover, wherein the terahertz wave transceiver is fixed on a side plate of a coal mining machine on one side above a scraper chain through the support unit, and the terahertz wave transceiver transmits acquired chain video or image signals to the terahertz image processing device;
the dust cover is arranged outside the terahertz wave transceiver and used for isolating external environment dust from the terahertz wave transceiver, a working surface made of transparent material is arranged on the dust cover, and a powder scraping mechanism is arranged on the working surface;
the dust detection sensor is used for detecting the dust amount near the dust cover in real time;
the terahertz image processing device, the dust detection sensor and the powder scraping mechanism are respectively connected with a computer through data lines.
Scrape whitewashed mechanism and include that motor, shaft coupling and L shape scrape the strip, wherein, the motor passes through the motor frame to be fixed in the outside of dust cover, and the motor output shaft passes through the shaft coupling to be connected with the one end of L shape strip of scraping, and L shape strip of scraping is contradicted with the working face external surface of terahertz wave transceiver and is connected.
The motor is a stepping motor.
The part of the L-shaped scraping strip, which is in contact with the working surface of the terahertz wave transceiver, is made of a soft material which is convenient to replace.
The soft material is soft plastic, rubber or a brush.
A monitoring method based on the scraper conveyor chain tension monitoring system comprises the following steps:
s1, selecting the scraper chain with the distance between the two scrapers to perform a tensile test on a fatigue testing machine, and measuring the force-deformation curve of the scraper chain and the deformation of the scraper chain when the scraper chain is broken S0;
s2, shooting a video of the scraper conveyor in the running process by using a terahertz imaging unit, selecting a picture at a certain interval t, identifying the distance L between two scrapers through a terahertz image processing device, and subtracting the initial distance L0 between the two scrapers to obtain the deformation S of the scraper chain;
s3, corresponding the deformation S of the scraper chain to the force-deformation curve of the scraper chain to obtain the tension F of the scraper chain, which is specifically as follows:
when S is less than 0, the scraper chain is in a loose state, and a chain tightening device of the scraper conveyor needs to be adjusted;
when S is more than or equal to 0 and less than 0.9S0, the scraper chain is in a normal working state;
when S is more than or equal to 0.9S0, the scraper chain is in a state close to fracture, and the coal conveying amount needs to be reduced in time;
the dust detection sensor transmits the detected real-time dust quantity signal to the controller, and the controller compares the real-time dust quantity signal with a preset dust threshold value, and specifically comprises the following steps:
if the real-time dust quantity signal does not exceed the maximum value of the dust threshold value, the controller controls the powder scraping mechanism to operate according to a first frequency;
and if the real-time dust quantity signal exceeds the maximum value of the dust threshold value, the controller controls the powder scraping mechanism to operate according to a second frequency, wherein the second frequency is 1.5-3 times of the first frequency.
The time t in step S2 is obtained by the following equation:
t=n*S0/(V1-V2)
wherein n is the number of the separated scrapers, V1 is the running speed of the scraper conveyor, and V2 is the running speed of the coal mining machine.
When the tension F is stable, increasing n; when the tension F fluctuates largely, n is decreased.
The step S3 in which the terahertz image processing apparatus recognizes the distance between the two squeegees specifically includes the steps of:
firstly, converting image information obtained by a terahertz wave transceiver into an electric signal;
then, denoising, smoothing and converting the electric signal to strengthen the boundary characteristic of a scraper in the image;
secondly, extracting and selecting characteristics, and extracting boundary information of the obtained scraper;
finally, a classifier design is carried out, so that the distance L between the two scrapers is obtained.
Has the advantages that: the invention provides a scraper conveyor chain tension monitoring system, which can monitor the tension of a scraper conveyor without damaging the scraper chain, realize the nondestructive monitoring of the scraper chain tension, judge the running state of the scraper conveyor based on tension data and provide a basis for equipment to adjust running parameters; meanwhile, according to the image presented by the terahertz imaging system, the vibration condition of the scraper chain is observed through visual inspection, and when the amplitude of the shaking of the scraper chain exceeds the width of the chain link, the running state of the scraper is unstable, and the running conditions of the scraper and a coal mining machine need to be adjusted in time.
Drawings
FIG. 1 is a schematic structural diagram of the present invention.
Fig. 2 is a schematic view of fig. 1 with the dust cover partially removed.
Fig. 3 is a view from direction ii in fig. 1.
Fig. 4 is a flowchart of a terahertz imaging unit.
FIG. 5 is a flow chart of an embodiment of the present invention.
The figure includes: 1. coal mining machine, 2, dust cover, 3, support unit, 4, middle groove, 5, scraper chain, 6, scraper, 7, Hertz wave transceiver, 8, motor, 9, coupling, 10 and powder scraping mechanism.
Detailed Description
The invention will be further explained below with reference to the drawings.
As shown in fig. 1, 2 and 3, a bracket 3 is fixed on a coal mining machine 1 through bolts, the other end of the bracket 3 is connected with a terahertz wave transceiver 7, a signal of the terahertz wave transceiver 7 is transmitted to an external board level circuit and a notebook through a wireless transmitter arranged on the bracket 3, a dust cover 2 is arranged on the outer side of the terahertz wave transceiver 7, a dust scraping device 10 is connected on the outer side of the dust cover 2 and is controlled to rotate by a stepping motor 8, and wires of the dust cover 2 and the dust scraping device 10 are connected to the outside through the bracket 3.
When the system is installed, the side of the dust cover 2 closest to the coal mining machine 1 is sleeved on the bracket 3, and the connecting part is welded; secondly, a terahertz wave transceiver 7 is installed and fixed on the bracket 3 by using a bolt; then the four walls of the dust cover 2 are installed, the periphery of the dust cover is welded with the surface which is installed in advance, and finally the side farthest away from the coal mining machine 1 is installed and fixed by bolts, so that the dust cover is convenient to disassemble during maintenance.
The main body of the dust cover 2 is made of a titanium alloy material, the bottom surface of the dust cover is made of a modified polypropylene material, the two materials have the characteristics of high strength, high temperature resistance, corrosion resistance and the like, the inner terahertz wave transceiver 7 can be protected from being influenced by external dust, falling coal blocks, corrosive liquid and the like, and normal work of the terahertz wave transceiver is guaranteed.
The dust scraping device 10 is controlled to rotate by a stepping motor 8, and the two are connected by a coupler 9. The selected stepping motor has the characteristics of high precision and forward and reverse rotation, the stepping motor is arranged on an external controller to pass through three processes of forward rotation, reverse rotation and stop, and when the speeds of the stepping motors are different, the running speed of the dust scraping device is changed; when the stop time is different, the running frequency of the device is changed, so that dust scraping movement with different frequencies and speeds can be realized by controlling the speed and the running of the motor, and the normal and efficient running of the terahertz imaging unit is ensured.
A layer of soft plastic convenient to replace is added on the working surface of the dust scraping device 10, so that dust on the dust cover is completely scraped.
As shown in fig. 4, the terahertz imaging unit transmits and receives signals through the terahertz transceiver, analyzes and processes the received information, and finally displays images of the blade and the chain on a computer.
As shown in fig. 5, the monitoring method includes the steps of:
and selecting the scraper chain with the distance between the two scrapers to perform a tensile test on a fatigue testing machine, and measuring the force-deformation curve of the scraper chain and the deformation of the scraper chain when the scraper chain is broken S0.
And (3) shooting a video of the scraper conveyor in the running process by using a terahertz imaging unit.
And selecting a photo at intervals of t, identifying the distance L between the two scrapers through an image identification system, and subtracting the initial distance L0 to obtain the deformation S of the scraper chain.
And (5) corresponding the S to the force-deformation curve of the scraper chain to obtain the tension F of the scraper chain.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be construed as the protection scope of the present invention.
Claims (8)
1. A monitoring method of a scraper conveyor chain tension monitoring system is based on the scraper conveyor chain tension monitoring system and comprises the following steps:
the terahertz imaging unit is used for detecting and scanning a scraper conveyor chain in transmission to generate a video or image signal of the chain, and comprises: the system comprises a terahertz wave transceiver, a terahertz image processing device, a support unit and a dust cover, wherein the terahertz wave transceiver is fixed on a side plate of a coal mining machine on one side above a scraper chain through the support unit, and the terahertz wave transceiver transmits acquired chain video or image signals to the terahertz image processing device;
the dust cover is arranged outside the terahertz wave transceiver and used for isolating external environment dust from the terahertz wave transceiver, a working surface made of transparent material is arranged on the dust cover, and a powder scraping mechanism is arranged on the working surface;
the dust detection sensor is used for detecting the dust amount near the dust cover in real time;
the method is characterized by comprising the following steps:
s1, selecting the scraper chain with the distance between the two scrapers to perform a tensile test on a fatigue testing machine, and measuring the force-deformation curve of the scraper chain and the deformation of the scraper chain when the scraper chain is broken S0;
s2, shooting a video of the scraper conveyor in the running process by using a terahertz imaging unit, selecting a picture at a certain interval t, identifying the distance L between two scrapers through a terahertz image processing device, and subtracting the initial distance L0 between the two scrapers to obtain the deformation S of the scraper chain;
s3, corresponding the deformation S of the scraper chain to the force-deformation curve of the scraper chain to obtain the tension F of the scraper chain, which is specifically as follows:
when S is less than 0, the scraper chain is in a loose state, and a chain tightening device of the scraper conveyor needs to be adjusted;
when S is more than or equal to 0 and less than 0.9S0, the scraper chain is in a normal working state;
when S is more than or equal to 0.9S0, the scraper chain is in a state close to fracture, and the coal conveying amount needs to be reduced in time;
the dust detection sensor transmits the detected real-time dust quantity signal to the controller, and the controller compares the real-time dust quantity signal with a preset dust threshold value, and specifically comprises the following steps:
if the real-time dust quantity signal does not exceed the maximum value of the dust threshold value, the controller controls the powder scraping mechanism to operate according to a first frequency;
if the real-time dust quantity signal exceeds the maximum value of the dust threshold value, the controller controls the powder scraping mechanism to operate according to a second frequency, wherein the second frequency is 1.5-3 times of the first frequency;
the terahertz image processing device, the dust detection sensor and the powder scraping mechanism are respectively connected with a computer through data lines.
2. The monitoring method of the scraper conveyor chain tension monitoring system according to claim 1, wherein the scraper mechanism comprises a motor, a coupler and an L-shaped scraper, wherein the motor is fixed on the outer side of the dust cover through a motor frame, an output shaft of the motor is connected with one end of the L-shaped scraper through the coupler, and the L-shaped scraper is in interference connection with the outer surface of the working surface of the terahertz wave transceiver.
3. The method of monitoring a scraper conveyor chain tension monitoring system of claim 2, wherein the motor is a stepper motor.
4. The method for monitoring the tension of the scraper conveyor chain of claim 2, wherein the part of the L-shaped scraper, which is in contact with the working surface of the terahertz wave transceiver, is made of a soft material which is convenient to replace.
5. The method of claim 4, wherein the soft material is soft plastic, rubber, or a brush.
6. The method of monitoring a scraper conveyor chain tension monitoring system of claim 1, wherein the time t in step S2 is obtained by the following equation:
t=n*S0/(V1-V2)
wherein n is the number of the separated scrapers, V1 is the running speed of the scraper conveyor, and V2 is the running speed of the coal mining machine.
7. The method of monitoring a scraper conveyor chain tension monitoring system of claim 6, wherein when the tension F is steady, n is increased; when the tension F fluctuates largely, n is decreased.
8. The monitoring method of the scraper conveyor chain tension monitoring system according to claim 1, wherein the step S3 in which the terahertz image processing device identifies the distance between the two scrapers specifically includes the following steps:
firstly, converting image information obtained by a terahertz wave transceiver into an electric signal;
then, denoising, smoothing and converting the electric signal to strengthen the boundary characteristic of a scraper in the image;
secondly, extracting and selecting characteristics, and extracting boundary information of the obtained scraper;
finally, a classifier design is carried out, so that the distance L between the two scrapers is obtained.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910306445.5A CN110040469B (en) | 2019-04-17 | 2019-04-17 | System and method for monitoring tension of chain of scraper conveyor |
| PCT/CN2019/120796 WO2020211381A1 (en) | 2019-04-17 | 2019-11-26 | System and method for monitoring tension of scraper conveyer chain |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910306445.5A CN110040469B (en) | 2019-04-17 | 2019-04-17 | System and method for monitoring tension of chain of scraper conveyor |
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| CN110040469A CN110040469A (en) | 2019-07-23 |
| CN110040469B true CN110040469B (en) | 2021-03-02 |
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| CN201910306445.5A Expired - Fee Related CN110040469B (en) | 2019-04-17 | 2019-04-17 | System and method for monitoring tension of chain of scraper conveyor |
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| CN (1) | CN110040469B (en) |
| WO (1) | WO2020211381A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110040469B (en) * | 2019-04-17 | 2021-03-02 | 中国矿业大学 | System and method for monitoring tension of chain of scraper conveyor |
| CN110659590B (en) * | 2019-09-06 | 2020-12-15 | 精英数智科技股份有限公司 | Monitoring method, device, equipment and storage medium of scraper conveyor |
| CN110789958A (en) * | 2019-11-05 | 2020-02-14 | 安徽华宏机械设备有限公司 | Detection system for abrasion of middle plate of middle groove of scraper conveyor |
| CN111498426B (en) * | 2020-04-10 | 2021-09-24 | 中国矿业大学 | A detection method for broken chain of double-chain scraper by structured light positioning and ranging |
| CN111891660A (en) * | 2020-07-31 | 2020-11-06 | 精英数智科技股份有限公司 | Belt slack monitoring method, device and system |
| CN113979017B (en) * | 2021-10-08 | 2023-07-25 | 辽宁工程技术大学 | A method and device for online fault monitoring of scraper conveyor |
| CN114097486A (en) * | 2021-12-15 | 2022-03-01 | 孙光群 | Self-interacting type increase production warmhouse booth |
| CN115744140B (en) * | 2022-11-19 | 2023-09-05 | 河南启欧通用机械有限公司 | State detection device for ultra-flat chain type scraper conveyor |
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| JP3066412B2 (en) * | 1996-05-13 | 2000-07-17 | 株式会社椿本チエイン | Chain elongation detection method and detection device |
| JPH10300426A (en) * | 1997-05-01 | 1998-11-13 | Tsubakimoto Chain Co | Roller chain wear detecting method and device |
| JP2000088526A (en) * | 1998-09-09 | 2000-03-31 | Kawasaki Steel Corp | Method and apparatus for diagnosing chain conveyer for failure |
| JP2000111318A (en) * | 1998-10-02 | 2000-04-18 | Tsubakimoto Chain Co | Method and device for measuring chain dimension |
| SE515475C2 (en) * | 1999-12-17 | 2001-08-13 | Paris Trae & Metall Ab | Method and apparatus for detecting and discharging faulty boards at a separation elevator |
| GB0508547D0 (en) * | 2005-04-28 | 2005-06-01 | Boc Group Plc | Conveyor system |
| JP4367644B2 (en) * | 2005-05-16 | 2009-11-18 | 株式会社ダイフク | Elongation detection system for conveyor chain |
| US8285494B2 (en) * | 2009-10-20 | 2012-10-09 | Tibor Vozner | Conveyor chain monitoring system and method |
| CN104444227A (en) * | 2014-09-30 | 2015-03-25 | 宁夏天地奔牛实业集团有限公司 | Broken chain monitor device and method for coal face scraper conveyer |
| FI128485B (en) * | 2015-07-06 | 2020-06-15 | Konecranes Oyj | Arrangement and method for inspecting condition of chain |
| CN105866031B (en) * | 2016-05-19 | 2018-09-18 | 山东省科学院自动化研究所 | A kind of scan table, scanned imagery device and method for Terahertz non-destructive testing |
| CN107777288B (en) * | 2017-11-06 | 2019-10-01 | 中国矿业大学 | A kind of drag conveyor chain rupture real-time monitoring system and monitoring method |
| CN108861426B (en) * | 2018-07-10 | 2020-04-03 | 太原理工大学 | Multi-parameter fusion recognition device for chain breakage fault of scraper conveyor |
| CN109142267B (en) * | 2018-09-07 | 2021-11-16 | 北京华航无线电测量研究所 | Real-time terahertz imaging device and method |
| CN110040469B (en) * | 2019-04-17 | 2021-03-02 | 中国矿业大学 | System and method for monitoring tension of chain of scraper conveyor |
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2019
- 2019-04-17 CN CN201910306445.5A patent/CN110040469B/en not_active Expired - Fee Related
- 2019-11-26 WO PCT/CN2019/120796 patent/WO2020211381A1/en active Application Filing
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| CN110040469A (en) | 2019-07-23 |
| WO2020211381A1 (en) | 2020-10-22 |
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